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DOE OSTI2026

Deployment of Traditional and Hybrid Machine Learning for Critical Heat Flux Prediction in the CTF Thermal-Hydraulics Code

Critical heat flux (CHF) marks the transition from nucleate to film boiling, where heat transfer to the working fluid can rapidly deteriorate. Accurate CHF prediction is essential for efficiency, safety, and preventing equipment damage, particularly in nuclear reactors. Although widely used, empirical correlations frequently exhibit discrepancies when compared to experimental data, limiting their reliability in diverse operational conditions. Traditional machine learning (ML) approaches have demonstrated potential for CHF prediction but often suffer from limited interpretability, data scarcity, and insufficient knowledge of physical principles. Hybrid model approaches, which combine data-driven ML with base models, mitigate these concerns by incorporating prior knowledge of the domain. This study integrates an externally trained purely data-driven ML model and two hybrid models (using the Biasi and Bowring CHF correlations) within the CTF subchannel code via a custom Fortran framework. Performance was evaluated using two validation cases: a subset of the Nuclear Regulatory Commission (NRC) CHF database and the Bennett dryout experiments. In both cases, the hybrid models demonstrated significantly lower error metrics compared to conventional empirical correlations, with the best models often reducing relative error by about 5 percentage points. The pure ML model achieved comparable accuracy, outperforming the hybrid Biasi model in the NRC test case (3.3% versus 5.5% relative error) but exhibiting slightly higher error against the hybrid Bowring model in the Bennett test case (7.7% versus 6.1%). Trend analysis of error parity indicated that ML-based models reduced the tendency for CHF overprediction, improving overall accuracy. These results demonstrate that ML-based CHF models can be effectively integrated into subchannel codes and could potentially increase performance compared to conventional methods.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Development of Real-Time System Identification to Detect Abnormal Operations in a Gas Turbine Cycle

Here, we present a novel online system identification methodology for monitoring the performance of power systems. This methodology was demonstrated in a gas turbine recuperated power plant designed for a hybrid configuration. A 120-kW Garrett microturbine modified to test dynamic control strategies for hybrid power systems designed at the National Energy Technology Laboratory (NETL) was used to implement and validate this online system identification methodology. The main component of this methodology consists of an empirical transfer function model implemented in parallel to the turbine speed operation and the fuel control valve, which can monitor the process response of the gas turbine system while it is operating. During fully closed-loop operations or automated control, the output of the controller, fuel valve position, and the turbine speed measurements were fed for a given period of time to a recursive algorithm that determined the transfer function parameters during the nominal condition. After the new parameters were calculated, they were fed into the transfer function model for online prediction. The turbine speed measurement was compared against the transfer function prediction, and a control logic was implemented to capture when the system operated at nominal or abnormal conditions. To validate the ability to detect abnormal conditions during dynamic operations, drifting in the performance of the gas turbine system was evaluated. A leak in the turbomachinery working fluid was emulated by bleeding 10% of the airflow from the compressor discharge to the atmosphere, and electrical load steps were performed before and after the leak. This tool could detect the leak 7 s after it had occurred, which accounted for a fuel flow increase of approximately 15.8% to maintain the same load and constant turbine speed operations.

algorithms↗

DOE OSTI2023

Tree-Based Ensemble Learning Models for Wall Temperature Predictions in Post-Critical Heat Flux Flow Regimes at Subcooled and Low-Quality Conditions

Accurately predicting post-critical heat flux (CHF) heat transfer is an important but challenging task in water-cooled reactor design and safety analysis. Although numerous heat transfer correlations have been developed to predict post-CHF heat transfer, these correlations are only applicable to relatively narrow ranges of flow conditions due to the complex physical nature of the post-CHF heat transfer regimes. In this paper, a large quantity of experimental data is collected and summarized from the literature for steady-state subcooled and low-quality film boiling regimes with water as the working fluid in vertical tubular test sections. In addition, a low-quality water film boiling (LWFB) database is consolidated with a total of 22,813 experimental data points, which cover a wide flow range of the system pressure from 0.1 to 9.0 MPa, mass flux from 25 to 2750 kg/m 2 s, and inlet subcooling from 1 to 70 °C. Two machine learning (ML) models, based on random forest (RF) and gradient boosted decision tree (GBDT), are trained and validated to predict wall temperatures in post-CHF flow regimes. The trained ML models demonstrate significantly improved accuracies compared to conventional empirical correlations. To further evaluate the performance of these two ML models from a statistical perspective, three criteria are investigated and three metrics are calculated to quantitatively assess the accuracy of these two ML models. For the full LWFB database, the root-mean-square errors between the measured and predicted wall temperatures by the GBDT and RF models are 5.7% and 6.2%, respectively, confirming the accuracy of the two ML models.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Optimization of a High Pressure Turbine Blade and Sector-Based Annular Rig Design for Supercritical CO2 Power Cycle Representative Testing

Abstract As part of the ongoing research into the design of hardware for zero emission cycles, a first-stage high-pressure turbine (HPT) blade is optimized for a 300 MWe supercritical CO2 (sCO2) power cycle using the surrogate-assisted genetic algorithm optimizer in Numeca FINE/Design three-dimensional with objectives of increasing efficiency and decreasing heat load to the blade. Supercritical CO2 property tables are constructed from NIST REFPROP data for the condensable gas simulation in FINE/Turbo. A detailed mesh sensitivity study is performed for a baseline design to identify the proper-grid refinement and efficiently allocate resources for the optimization. Seventy design variables are selected for the initial population generation. Self-organizing maps are then used to focus the design variables on the most important ones affecting the objective functions. The optimization results in approximately 3000 three-dimensional Reynolds Averaged Navier Stokes simulations of different blade shapes with increases in efficiency of up to 0.85% and decreases in heat load of 14%. Families of blade shapes are identified for experimental testing in an annular rig at the Purdue Experimental Turbine Aerothermal Laboratory. A design to adapt the annular cascade for testing optimized geometries is introduced, which features eccentric radius sectors allowing for scaled-up geometries of sCO2 optimized blade profiles to be tested at design cycle representative conditions at high Reynolds numbers in dry air. Analysis into the effects of Reynolds number, working fluid, and geometric relations are presented to prove the efficacy of the test method.

Engineering↗

DOE OSTI2025

Mitigation of Boiling-Induced Thermal Degradation Using Microporous Nickel Inverse Opals Structures

Engineered microporous structures have received much attention in high-heat-flux electronics cooling due to their high thermal conductivity and permeability, and large surface area for heat transfer, but are susceptible to boiling-induced thermal degradation. Here, this study investigates the efficacy of nickel inverse opals (NiIOs) in mitigating structural degradation caused by corrosion-assisted erosion during pool boiling with water as the working fluid. First, we compared the reliability of NiIOs to copper inverse opals (CuIOs) for a 3-day pool boiling test at constant heat flux. The NiIOs demonstrated superior resistance to thermal degradation due to their inherent corrosion resistance and mechanical strength. Subsequently, we conducted a more controlled experiment to show the effect of heat flux on the degradation of the NiIOs while excluding the effect of temperature variations. Pool boiling tests of 20-μm-thickness NiIOs covering an area of ∼11 × 11 mm 2 with a 2.5 × 2.5 mm 2 heater at the center were conducted at heat flux levels of 20%, 40%, and 60% of the critical heat flux (CHF) for 3 days. The NiIOs subjected to heat flux levels of 20% and 40% CHF showed minimal degradation, while the sample subjected to 60% CHF showed erosion on the top surface due to higher bubble formation and departure rate. These results show the potential of NiIOs as a promising solution for long-term thermal management in high-power electronic devices, although design considerations for maximum allowable heat flux are necessary for reliable operation.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Thermal-Mechanical Analysis of an Additive Manufacturing Ceramic Heat Exchanger for High-Temperature Recuperator in a sCO2 Power System

Supercritical CO2 (sCO2) Brayton power cycle can be configured in a closed-loop power system and has a potentially high cycle efficiency. Compactness and high efficiency of a sCO2 power block make the sCO2 Brayton cycle a versatile power cycle in broad applications. While many heat sources are of sufficient intensity to produce high temperature working fluids to achieve high cycle efficiency, the thermal-mechanical stability of traditional materials (e.g., steels and nickel-based superalloys) used in construction of heat exchangers and turbine components limits the operating conditions and thus thermodynamic efficiency of the system. This effort seeks to establish the viability of ceramic heat exchanger technologies for the most extreme operating conditions envisioned for power generation and other high temperature processes. Heat exchangers constructed from ultra-high temperature ceramics, a class of extreme environment materials featuring melting points (Tmp.) above 3000 degrees C, is particularly appealing for sCO2 Brayton cycles given their ultra-low creep rates and very high retained strength at low homologous temperatures (i.e., T < 0.5 Tmp., or at least 1500 degrees C). To translate these materials properties to ultra-high temperature heat exchangers, innovations are required in ceramic manufacturing techniques to realize the complex architectures featured in compact heat exchangers with high power density. With appropriate processing, ZrB2-SiC based compositions can be sintered to near full density and shaped into complex topologies via ceramic additive manufacturing methods. This paper analyzes heat exchanger designs and explores thermal-mechanical implications of the operating environment. Thermal flow, heat transfer, and conjugate mechanical analyses provide insights into benefits and risks associated with the design approach.

additive manufacturing↗

DOE OSTI2022

Diffusion bonded compact heat exchanger in Inconel 740H for high temperature and high-pressure applications

It is desired to develop heat exchangers able to be operated at high temperatures (750°C) and pressures (3636 psi) for use in advanced Brayton power cycle. Conventional materials have not had the high strength at temperature required for these applications previously, however a fairly new material Inconel 740H developed by Special Metals for the ultra-supercritical water fossil industry has shown good performance under these conditions. In further efforts to capitalize on these new high strength high temperature alloys CompRex has developed a diffusion bonding procedure capable of alloying compact high effectiveness heat exchangers that can perform under these high temperature and high-pressure conditions. Initial tests of the heat exchanger are being conducted at the University of Wisconsin using supercritical CO2 working fluid. The bonding process has been adjusted such that the strength of the bonded block has achieved over 90% yield and tensile strength of the 740H base material values. Grain size before and after bonding were measured to determine the extent of grain growth and grain diffusion across the interface. A discussion of the heat exchanger design, etching and initial tensile tests on sample bonds will be discussed.

14 SOLAR ENERGY↗

DOE OSTI2022

Convective Heat Transfer Potential of Particles/Airflow Through Single Cell Thick Additively Manufactured Octet-Shaped Lattice Frame Material

Abstract Particle-to-Supercritical Carbon Dioxide (sCO2) heat exchangers are one of the most critical components of the next-generation Concentrating Solar Power (CSP) plants. There have been several efforts to enhance the overall heat exchanger performance which essentially comprises of thermal resistances offered by sCO2 channel, wall (separating sCO2 with particles) thickness, particle-wall contact resistance and particle-side effective heat transfer coefficient. This study is focused towards reducing the particle side thermal resistance by incorporating single unit cell thick reticulated Octet lattice frame structures on the falling particle side to enhance the effective thermal conductivity of the particle channel and to enhance convective heat transfer between the falling particles and the solid phase of the falling particle channel (endwalls and fibers). Steady-state experiments were conducted to measure the effective thermal conductivity of lattice frame material for two cases: a) when void space was occupied by air, b) when void space was occupied with particles. Further, convective heat transfer experiments have been conducted with both air (steady-state) and particles (quasi steady-state) as “working fluid” for panels sandwiching the Octet array. Three different lattice porosities ranging from 0.75 to 0.9 have been tested for a wide range of air flow rates and a fixed particle flow rate (highest potential).

Aider, Youssef↗

DOE OSTI2020

ALLOY SELECTION AND C-276 CODE DESIGN VALUE EXTENSION FOR ADVANCED MOLTEN SALT TECHNOLOGY TEST FACILITIES EXPERIMENTATION

Molten halide salts are being considered as working fluids for nuclear and concentrated solar power applications. High temperature molten fluoride and chloride salts are known to preferentially attack and deplete Cr in alloys, which leads to the use of high-Ni lower-Cr alloys in test facilities for advanced Molten Salt Technology. Alloys 600 and C-276 are two commercially available Ni alloys that have moderate Cr contents and are qualified to the maximum temperature of 649°C and 677°C (1,200°F and 1,251°F), respectively, in the Boiler and Pressure Vessel Code. Both alloys have good corrosion resistance to acids, are resistant to stress-corrosion cracking, and have long track records of use in the chemical industry. Comparatively, Alloy C-276 has a similar Cr content but much higher allowable stresses for temperatures greater than 600°C (1,112°F). Therefore, it has been considered as a structural material for test facilities that require operations at 700°C (1,292°F) or greater to develop high-temperature Molten Salt Technology. To meet the requirements, the current code design values were extended based on some experimental data. Analysis showed that above current Codified maximum temperature, strength of the alloy is mainly controlled by creep rupture life under the average stress, although the Sc creep rate criterion is close to the Favg.Savg rupture criterion. This paper presents the intended test facilities and the design requirements, alloy selection considerations, literature review, data analysis, and proposed allowable stress extension based on some creep test data for C-276 at temperatures greater than 677°C (1,251°F). Further research activities are also briefly mentioned.

Ren, Weiju↗

DOE OSTI2021

High-Temperature Compatibility of Structural Alloys with Supercritical and Subcritical CO 2

In searching for new working fluids for power generation, supercritical CO 2 (sCO 2 ) offers some attractive features for efficient cycles. However, compatibility with structural alloys is a concern. NiCr-based alloys have excellent compatibility at 600°-800°C at 20-30 MPa sCO 2 . However, conventional steels have restrictions in temperature because of carburization and accelerated oxidation in sCO 2 , similar to observations in CO 2 . To assess the impact of carburization on steel mechanical properties, small (25mm long) dogbone tensile bars are being exposed and tested after exposure at 450°-650°C. Only highly alloyed advanced austenitic steels are resistant to carburization at 650°-750°C, suggesting that Crrich oxide scales are good barriers to C ingress. Above 800°C, it is only possible to conduct subcritical evaluations at this time, but initial results suggest most conventional high-temperature Fe- and Ni-based alloys are more rapidly degraded by CO 2 at higher temperatures. Coatings are a potential solution that require more study.

36 MATERIALS SCIENCE↗

DOE OSTI2020

srlife

Solar receiver structural life estimation tool. This software estimates the life of a tubular concentrating solar power receiver given user input describing the working fluid pressures and temperatures. sf-20-068

Messner, Mark↗

DOE OSTI2021

Experimental Investigation of Melting and Solidification Processes of Phase Change Material Heat Exchanger

Rapid development and validation of PCM embedded heat exchangers (PCM-HX) concepts warrant a purpose-built test bench. This paper describes a test facility built for testing various PCM-HX configurations and phase change temperatures that will serve to validate the performance of novel PCM-HX designs. The entire test rig is placed in a temperature-controlled environmental chamber. Inside the PCM-HX containers, up to 48 T-type thermocouples can be spatially distributed on and around the tubes depending on the HX type to capture the phase change process over time. In this paper, a straight tube embedded in PCM having a phase change temperature of 37°C in cylindrical containers is tested. The PCM-HX uses water as an in-tube working fluid. Based on the measured data, the energy balance is analyzed, and its temperature distribution is presented. Here, the maximum deviation between the predicted stored energy and the energy stored calculated from experimental measurements is less than 5%.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Heat transfer and visual observation of pool boiling of next-generation low-pressure refrigerant: R1336mzz(Z)

R1336mzz(Z) is a non-flammable and non-toxic hydrofluoroolefin (HFO), which is a potential alternative working fluid for multiple applications such as centrifugal chillers, industrial high temperature heat pumps, and Organic Rankine Cycles. Pool boiling is one of the primary heat transfer modes in shell-and-tube evaporators, and there is limited data for R1336mzz(Z) due to its recent introduction. This study investigated the pool boiling characteristics of R1336mzz(Z) using a closed-loop apparatus. Heat transfer coefficients on a smooth aluminum surface were measured at various heat fluxes with a heating block, and the results were compared to predictions from various correlations. Additionally, a high-speed camera was employed to visualize and analyze the pool boiling behavior of this next-generation low-pressure refrigerant.

Yang, Cheng-Min [ORNL]↗

DOE OSTI2020

Terry Turbopump Expanded Operating Band Modeling and Simulation Efforts in Fiscal Year 2020 - Progress Report

The Terry Turbine Expanded Operating Band Project is currently conducting testing at Texas A&M University as part of a revised experimental program meant to supplant previous full-scale testing plans under the headings of Milestone 5 and Milestone 6. In consultation with Sandia National Laboratories technical staff and with modeling and simulation support from the same, the hybrid Milestone 5&6 plan is moving forward with experiments aimed at addressing knowledge gaps regarding scale, working fluid, and turbopump self-regulation. Modeling and simulation efforts at Sandia National Laboratories in FY20 fell under the broad umbrella of Milestone 7 and consisted exclusively of MELCOR-related tasks aimed at: 1) Constructing/improving input models of Texas A&M University experiments, 2) Constructing a generic boiling water reactor input model according to best practices with systems-level Teny turbine capabilities, and 3) Adding code capability in order to leverage experimental data/findings, address bugs, and improve general code robustness Project impacts of the Covid-19 pandemic have fortunately been minimal thus far but are mentioned as necessary when discussing the hybrid Milestone 5&6 progress as well as the corresponding Milestone 7 modeling and simulation progress.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Oxy-Combustion System Process Optimization

The overall objective of this work is to develop a new chemical absorbent-based, high pressure, CO 2 purification system to remove the residual oxygen that currently contaminates the recovered CO 2 , and to optimize the Pressurized Oxy-Combustion (POxC) process to minimize the Cost of Electricity (COE) generated in this advanced combustion process. TDA developed and validated the performance of the oxygen removal system for CO 2 purification. In collaboration with the Advanced Power & Energy Program (APEP) of University of California, Irvine (UCI), we optimized the POxC process, including thermal management, heat integration, and power cycle optimization using process design and modeling supported with Aspen Plus® process simulations. The techno-economic analysis results indicate that the pressurized oxycombustion coal power plant with Ion-transport membrane (ITM) air separation unit (ASU) (Case 2 – 30.55%) does not show an advantage over a cryogenic ASU (Case 1 – 31.24%) while TDA’s sorption-based ASU (Case 4 - 32.61%) shows a significant advantage over the cryogenic ASU (Case 1 – 331.24%). The specific plant costs show a wide range with a low of $2544/kW for Case 11C (TDA ASU, co-sequestering the SO x , and ultra-supercritical steam cycle) to a high of $2975/kW for Case 12A (cryogenic ASU and sCO 2 cycle). In general, the ITM ASU based cases have lower specific plant costs than the corresponding cryogenic ASU based cases while the TDA ASU based cases show the lowest specific plant costs. The main reason for lowering these costs is the higher overall plant thermal efficiency which decreases the plant cost on a $ per kW basis. Next comparing the cases with different power cycle working fluid conditions in terms of temperature and pressure while all utilizing steam, similar trends as the plant costs may be observed. However, with the supercritical CO 2 (sCO 2 ) cycle, the increase in thermal efficiency of the sCO 2 cycle was not able to offset its increase in plant cost making the plant costs higher than those of the corresponding steam cycle cases. The Cost of Electricity (COE) again shows similar trends as the specific plant costs. The COE for Case 11C at $110.1/MWh is also the lowest, but among all cases that do not co-sequester the SO x , Case 12C (TDA ASU and sCO 2 cycle) has the lowest COE at $\$$117.5/MWh while the highest is for Case 8A (cryogenic ASU and supercritical steam cycle) at $130.4/MWh.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2021

Advancements Toward ASME Nuclear Code Case for Compact Heat Exchangers

Our research team proposes to advance the state of the ASME section III code (nuclear service) for Compact Heat Exchangers (CHX). This work will improve the technical state of CHXs and lay the foundation necessary for these heat exchangers to be certified for use in nuclear service. During the course of this work, we will advance the understanding of the performance, integrity, and lifetime of the CHXs for use in any industrial application, making their use more attractive and accessible to the industry. We will do this by developing qualification and inspection procedures that utilize Non-destructive evaluation (NDE) and advanced in-service inspection techniques, with insight from the industrial utility leader EPRI. We have enlisted colleagues at MPR Associates (MPR), an elite nuclear code consulting firm, who are experts on the ASME section III code and who, with input from members of the ASME section III committee, will direct the testing and help develop a series of documents that define the rules and regulations for use of the CHX. Colleagues at North Carolina State University (NCSU) and Oregon State University (OSU) will conduct extensive tensile, creep, and fatigue experiments on diffusion bonded samples (manufactured by US-based Vacuum Process engineering) along with modeling using the elastic perfectly plastic assumptions and comprehensive full inelastic finite element analysis (FEA). This work will allow analysis by design and confidence in the strength of different internal structures. To ensure industry acceptance and long term confidence, team members at the University of Wisconsin–Madison (UW), University of Michigan (UM), Georgia Tech (GT), and the University of Idaho (UI) will extensively test prototypic heat exchangers manufactured by US-based manufactures CompRex and Vacuum Process Engineering (VPE), a leader in the development of advanced CHX. This testing will include the use of various working fluids (salt, sodium, helium, and sCO2) to evaluate operational issues as well as structural integrity under the most severe conditions. Post-test analysis of the tested CHXs coupled with pre/in-service/post NDE (ultrasonic and radiography) led by the Electric Power Research Institute (EPRI) will be incorporated into the development of the rules and regulations for their use in nuclear service.

42 ENGINEERING↗

DOE OSTI2021

Wear in particle based CSP systems from particle abrasion and attrition at high temperature

High temperature particle-based receivers offer distinct advantages over conventional molten salt receivers due to their ability to achieve temperatures above 700 ºC, direct absorption of solar energy as they fall through a beam of concentrated sunlight, and the relative ease of storage (and retrieval using a secondary working fluid) in insulated storage tanks. The use of particles, however, also raises concerns with material degradation from the flow of hot or cold particles through discharge hoppers or along the inner receiver surfaces and other system components (e.g. tubes, valves etc.), depending on operating mode of the receiver. The flow of particles over surfaces may result in loss of material from abrasive wear, impact erosion from impingement under gravitational fall and particle attrition as particles fall and move on top of each other. In the present study, the performance of candidate materials and particles were evaluated through a series of abrasion erosion and particle attrition experiments at room temperature as well as at 800 °C. Candidate materials were subject to abrasive wear from particles at low particle to material velocities inside a resistance heated kiln, and analyzed for changes in mass and surface morphology using cross-sectional scanning electron microscopy (SEM) and energy dispersive x-ray spectroscopy (EDS) tests. The wear rate for different specimens was noted to be largely driven by the strength of chromia scales built on the specimens from exposure to high temperature. Particle attrition measurements explored the susceptibility of particles to breakdown from particle to particle interaction and the generation of fines from this process. At the low velocities expected in particle based CSP plants, the particles tested exhibited near negligible breakdown. However, changes in the particle hardness at 800 ºC resulted in a significantly higher particle breakdown to sizes <40 microns raising potential environmental concerns. In addition to particle breakdown, it was also noted that the sample had oxides from the stainless steel test setup mixed in with the particles. Similar oxides can be expected to turn up in the utility scale particle based CSP plants as well. The presence of oxide was also noted to affect the solar absorptivity of the mixture compared to a clean initial specimen, potentially resulting in a change in the overall efficiency of the CSP plant.

14 SOLAR ENERGY↗

DOE OSTI2021

Characterization of Embedded Sensors in Stainless Steel Test Articles and Design/Planning for MAGNET Testing

The nuclear industry is pursuing microreactors that can be factory assembled and deployed to remote regions for reliable power generation. One class of microreactors uses a monolithic metal core block coupled to heat pipes for heat rejection, which results in significant thermal stresses in the monolithic structures. This work describes the initial characterization and test plan for evaluating stainless steel test articles fabricated with embedded sensors for measuring heat pipe performance limits, as well as spatially distributed temperatures and strains during electrically heated thermal testing. The electrically heated testing will be performed in the non-nuclear Microreactor Agile Non-Nuclear Testbed and Single Primary Heat Extraction and Removal Emulator facilities located at Idaho National Laboratory. The goals of these tests are to (1) accurately monitor temperature and strain distributions that result from differential thermal expansion in the test articles and (2) quantify heat rejection limits of heat pipes as a function of operating temperature and working fluid during steady-state and transient operations. More generally, the ability to monitor component and system health during microreactor operation is attractive for providing a high sensor density to inform a limited number of microreactor operators to ultimately reduce operation and maintenance costs and move toward semi-autonomous operation. This report discusses the characterization of embedded thermocouples and fiber optic sensors in relevant test articles, including cylindrical pipes and hexagonal monolithic test articles for heat pipe-based reactors. The sensors were embedded by placing them in machined channels and then building up additional material by using ultrasonic additive manufacturing (UAM). UAM is a solid-state welding process that uses downward pressure and a lateral scrubbing motion to bond thin metal foils to a base material layer by layer. The ultrasonic welding process relies on the plastic deformation of the metal—as opposed to typical melting and solidification—to break oxide scales and bond the metal layers. The characterization of these embedded sensors included evaluating fiber optic signal attenuation, observing residual strain in the fibers, investigating microstructural and mechanical aspects, and demonstrating the sensors under various thermal loads and acoustic vibrations. Post-embedding characterization showed a fine grain structure (<1 μm) near the interfaces of the bonded foils as a result of severe deformation from the welding process. A large increase in hardness was observed at the foil interfaces and the fiber/matrix interface compared with the bulk matrix. Even when compared with the SS304 interfaces, the higher hardness observed around the embedded fiber suggests a higher degree of deformation due to the soft metal coating around the silica fiber core. The distributed fiber-optic temperature sensors and embedded thermocouples reliably measured temperature distributions during steady-state and transient thermal testing. The embedded fiber-optic sensors reliably measured strain during both transient and steady-state testing and properly identified resonant frequencies during acoustic testing.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗